高速超高速磨削用轻质CFRP基体砂轮控性控形基础研究

Aiming at facts that frequently used CBN grinding wheels with metal body are restrained to be utilized extensively due to the greater mass, lower strength-to-weight ratio and specific modulus，together with overload on the spindle, high power consumption, large grinding wheel deformation, poor vibration resistance etc, all which result in instability of machining precision and surface quality, the subject aims to carry out deep and systematic researches on key scientific issues on performance-control, shape-control and grinding mechanism of lightweight grinding wheel with CFRP material for high speed and ultra-high speed grinding. In this process, it will get hold of dynamic optimization design theory and method, and make it revealed about influence rule of changeable thickness and cross section on strength and inner stress of CFRP grinding wheel. Meanwhile, deformation and vibration of CFRP grinding wheel will get reduced in high speed and ultra-high speed grinding process, which makes it possible to improve and enhance machining precision and surface quality. Accompanying with grinding theory and experimental research on high speed and ultra-high speed grinding with CFRP grinding wheel, material deforming and removal mechanism will be revealed, as well characterization methods on grinding performance will be obtained, all which provides theoretical and technical support on high speed and ultra-high speed technology behaving stably on comprehensive advantage such as high efficiency, good quality and low cost in production application.

针对目前钢基体CBN砂轮由于质量大、比强度及比模量较低，高速超高速磨削中主轴负荷大、功耗高、砂轮变形大、抗振性差，导致加工精度、加工表面质量不稳定的问题，面向高速超高速磨削用轻质CFRP基体砂轮的控性、控形与磨削机理等关键科学问题开展深入和系统研究，掌握高速超高速CFRP砂轮的动力学优化设计理论与方法，揭示变厚度变截面对CFRP砂轮强度及内应力大小与分布的影响规律，减小高速超高速CFRP砂轮的变形和振动，有效改善和提高加工精度与加工表面质量。通过CFRP砂轮的高速超高速磨削加工理论与试验研究，揭示材料激变行为与去除机理，掌握磨削性能表征方法，为确保高速超高速磨削技术在生产应用中稳定发挥高效率、高质量和低成本的综合优势提供理论与技术支撑。

超高速磨削技术具有磨削力小、加工效率高等优点，在航空航天等领域难加工材料关键部件加工中具有广阔应用前景。目前钢基体CBN砂轮质量大、比强度及比模量较低，高速超高速磨削中主轴负荷大、功耗高、砂轮变形大、抗振性差，导致出现了加工精度、加工表面质量不稳定的问题。有鉴于此，本项目提出研制高速超高速磨削用可控性控形的轻质超硬磨料砂轮CFRP基体的构想。通过建立和完善高速超高速磨削用CFRP砂轮综合性能评价平台、开展高速超高速CFRP砂轮材料-结构一体化设计以及少无缺陷制备与低损伤加工研究、揭示难加工材料高速超高速磨削去除机理研究与加工用量优化，攻克超高速砂轮质量大、抗振性差的难题，研制满足超高速磨削对砂轮安全、主轴载荷、磨削质量综合要求的新型CFRP砂轮，为解决制约难加工材料超高速磨削技术发展的工具与工艺瓶颈问题奠定科学基础。.完成的主要工作包括：.（1）建立了超高速磨削砂轮综合性能评价平台，研究了金属基体砂轮和CFRP砂轮在超高速磨削时的动静态特性，为后续CFRP砂轮研制工作提供理论与技术支持。.（2）建立了CFRP砂轮基体仿真模型，揭示了板材厚度和铺层工艺对砂轮性能的影响规律，发展了基于各向同性设计理论的CFRP砂轮基体动力学优化方法。.（3）研究了基于少无缺陷制备与低损伤加工技术的等强度砂轮基体加工方法，获得了等强度砂轮基体所满足的截面形状和曲面特征参数，制备了相应的CFRP砂轮，通过安全回转测试保证了砂轮的可靠性。.（4）以镍基高温合金为对象，开展了超高速磨削仿真与试验，分析了材料去除过程和加工质量，提出了CFRP砂轮超高速度磨削的“速度效应”与“尺寸效应”的表征方法，验证了CFRP砂轮超高速磨削对于改善高温合金等材料难加工性的优势。